Emerson Confidential
Digital Transformation of Refinery
Operations to achieve Top Quartile
Performance
Sanjay Thakker
Sources: Refining and Petrochemical Benchmarks,
API, Solomon, OSHA, IHS Markit and Company Reports
Safety
Production
4% higher availability
Half the
maintenance
costs
3X fewer
recordablesand process
incidents
20% lower operating costs
Reliability
Emissions
Process
Incidents
4th 1stQuartiles
Utilization
4th 1stQuartiles
Energy Use
CO2 Emissions
4th 1stQuartiles
Availability
Maintenance
4th 1stQuartiles
30% lower emissions
30% less energy use
Operating Costs
Recordables
10% higher Utilization Rate
Approximately
ONE TRILLION
DOLLARSin company value is
lost every year to
performancesuboptimal operating
Industry Benchmarks Reveal Significant Business Improvement Opportunities from
Average to Top Quartile Performers
• Emerson Innovations Will Power Customer’s Strategies Across Essential Competencies
Automated Workflow
Decision Support
Workforce Upskilling
Mobility
Change ManagementTime
Workforce
Productivity
Adoption of
Best-In-Class
Behaviors 5 ESSENTIAL COMPETENCIES
OF DIGITAL TRANSFORMATIONIncremental
Continuous
Improvement
The Next Era of Value Creation Will Be Enabled by Digital Technologies
Emerson Confidential
Safety
Energy & Emissions Production
Cybersecurity
Asset
Health
Location
Awareness
Safety
Shower
Corrosion
Monitoring
Leak
Detection
Collaboration
Platform
Mobile
Worker
Asset Monitoring
Electronic
LogsIntelligent
Calibration
Diagnostic
Heat
Exchanger
Cooling Tower
EMIS
Steam Traps
Tank
Monitoring
BlendingAdvanced
Control
Digital
Twin
Procedural
Automation
Machine
Learning
Flare
Monitoring
Pumps
Reliability
Digital Technologies supporting Operational Excellence Performance
Asset Performance Platform
Asset Health
Asset Health & Efficiency
Device & Machinery Diagnostics
Digital Twins
CONDITION-BASED PRE-CONFIGURED INTEGRATED MULTI-ASSET ADVANCED & ENTERPRISE ASSET OPTIMIZATION
Connectivity Analytics ServicesData
Emerson’s Analytics Portfolio
DiagnosticsRule-Base
Analytics
First Principle
Analytics
Advanced
Analytics
Smart Devices
Embedded Diagnostics
Device Alerts
Logics
Algorithms
Scenarios
Formulaic
Thermodynamics
Historical Data
Known FMEAs
Root Cause Analysis
Anomaly Detection
Machine Learning
Unknown FMEAs
Cross Correlations
Ha
rdw
are
So
ftw
are
Obsidian
Health
Performance
Energy
InsightAMS Device Manager
AMS Machinery Manager
Application-Specific
KnowledgeNet®KNet Analytics
Deep Domain & Application Expertise Data Science
Asset Performance Platform
Asset Health
Asset Health & Efficiency
Device & Machinery Diagnostics
Digital Twins
CONDITION-BASED PRE-CONFIGURED INTEGRATED MULTI-ASSET ADVANCED & ENTERPRISE ASSET OPTIMIZATION
Connectivity Analytics ServicesData
Scalable Analytics Portfolio Solves Real-World Problems
Easy-to-use analytics and dashboards with
pre-configured algorithms
Customizable multi-asset models for
health and efficiency
Abnormal Situation Identification
Relevant Time Asset Monitoring
Pre-Packaged Analytics
Simple, Actionable Interface
Minimal Configuration
Seamless Integration
Plant, Unit, and
Equipment Health
Equipment
Performance &
Efficiency
Management of
Energy Consumption,
Costs, and Emissions
KnowledgetNet(Knet)
Machine Learning Analytics Portfolio Solves Problems offline and online
Is most comprehensive suite of Machine Learning & FMEA based analytics powered
by Prescriptive and Predictive maintenance providing automated Root Cause
analysis with corrective actions and Dynamic targeting.
Pump App: Challenges For Industrial Users & Solution
Customizable multi-asset models for
health and efficiency
Statistically, pumps will fail or suffer degraded operation every 12 months
Reactive maintenance results in 50% higher coststhan preventative
Poor equipment reliability impacts HSSE in the form of safety incidents, regulatory fines and process shut downs
Cavitation, Premature Wear
Detection
CALCULATED INSIGHTS
• Vibration monitoring
• Cavitation
• Pump pressure differential
• Process variable thresholds
based on baseline capture
• Pump health index
• Abnormal situation awareness in
the form of alerts
Impact on OperationsChallenges Acoustic Monitoring of PRV’s
Comprehensive PRV monitoring for
closed recovery and flare systems
enables immediate identification and
response to source
control
Sector Rule Emissions Complexity:
§63.648 Equipment leak standards-
Operators would install electronic
monitors on PRDs that vent to
atmosphere to identify and record the
time and duration of each pressure
release
§63.670, paragraphs (o)(3) Identify
the source of release on the flare
systems for root cause analyses
Non-intrusive wireless solution utilizing
acoustic / temperature transmitters to
detect the PRV release in real-time.
Detected at least 200 incidents.
Identified 20 “bad actors” and the
problems were resolved within an hour.
Increased throughput and revenue of the
units:
ROI: 270%
Client said, “The increased throughput
and revenue was an unexpected bonus.”
Flare Systems – Efficient and Reliable Compliance to the New
Regulations
Emerson Committed to Environmental Solutions :
Emerson Presentations and Seminar 4C Conference Feb 2019
Top Quartile Environmental and Plantweb Overview
What’s New under Refining Sector Rule (EPA 40CFR63)?
Challenges in Flare Measurements and Monitoring
• Wireless Measurements
• Flow Monitoring Solutions
• Gas Composition Monitoring and EPA Reporting Systems
Safety/Hazardous Monitoring Technologies
Improving Emissions and Safety Combustion Solutions for Fired
Heaters
Leak Detection and Repair (LDAR)
• Pressure Relief Valves: Best Practices in Reducing Emissions
• Reducing Pump Risks with Real Time Monitoring
Workshop Collaboration and Next Steps
10
Emerson Confidential
Application Real-time Insight Annual Savings ($M) ROI (Months)
Steam Trap Monitoring Energy waste and emissions $0.4 - $0.6 7 months
Pump Monitoring Cavitation, pump health $0.5 - $0.6 11 months
Pressure Gauge Monitoring Process pressure, gauge health indication $0.4 - $0.6 12 months
Heat Exchanger Monitoring Fouling and efficiency $2.7 - $3.6 3 months
Cooling Tower Monitoring Efficiency and health $0.3 - $0.5 4 months
Mobile Workforce Startup and turnaround efficiency 1.6-2.1 3 Months
Air Cooled Heat Exchanger Monitoring Fan health and fouling 0.9-1.1 13 Months
Safety Shower and Eye Wash Monitoring Instant trigger indication Per incident Safety
TOTAL$8.8M - $11.7M
Savings Per Year6 months
* This chart is based on a 250,000 bpd refinery analysis by Emerson
Real-Time Monitoring with Plantweb Insight Creates Substantial Opportunities for High
Value Savings
1.2 MM/BPD
Refinery – 5%
Utility Costs
Savings –
$30million/Yr;
300,000 T/ Yr
Reduced CO2
Assumed pricing: Fuel - $5/ BTU; Steam - $8/ BTU;
Power - $60/ MWH; 1,200,000 BPD Refinery
Why is Energy Management and Control Important?
Typical Financial Flows in Utilities for Large Refinery
12
Emerson Confidential
ProcessBoilers/ GT’s
Fuel
System
Control/
Distribution
Steam
Control/
Distribution
Electrical
Generation/
Distribution
Hydrogen
Generation/
Distribution
External
Supply
Electrical
External
Supply
Fuel
External
Supply
Water
$1,200,000/Day$1,500,000/Day
$1,000,000/Day $1,000,000/Day
$600,000/Day
$400,000/Day$6,000/Day
$200,000/Day
$1,500,000/Day
$200,000/Day
$6,000/Day
$300,000/Day
$6,000/Day
$25,000/Day$25,000/Day
$18,000/Day
What Energy “Information” Often Looks Like Today
Reporting is based upon
allocation using various
custom calculations and
spreadsheets
Only looks in the past and
doesn’t detail why
consumption changed
Difficult to understand root-
cause of problems when
much measurement is
missing
Emerson Confidential13
Energy Management Solution
• Expert rules monitor energy performance and compares to targets
• Dynamic targeting considers process scenarios and uses regression models to identify energy performance baseline.
• Automated root cause analysis to pinpoint source of detected energy inefficiencies
• Interactive workflow provides operations with corrective actions in line with best practices
• Online visualization through web dashboards and reports
14Emerson Confidential
Example: Saudi Aramco Abqaiq Plants
• Biggest oil processing and crude stabilization facility in
the world – 15% of global oil production
• Main oil processing center for Arabian Extra Light (AXL)
and Arabian Light (AL) crude oils, with a capacity of
more than 7 million bpd
• 3 main processing operations: oil, NGL and utilities.
• Average energy consumption: ≈ 30 KBTU/Boe
• Digital Transformation Vision
• Several World Awards in Technology Innovation
Ref: EGUE 3-161972; “Combining AI and Prescriptive Analytics for reaching realistic Operation
Efficiency and Optimization”; Mohammed Batouq; Ali Alwadi; Samy Achour; Mark Nixon
Deliverables
Key Performance Indicators
• 7 Plant-wide KPIs
• More than 350 sub-KPIs
• Energy Savings and Costs
Root Cause Analysis
• 7 drilldown models
• More than 100 root causes
Web –based Dashboards
• 7 KPIs monitoring dashboards
• 14 Optimization dashboards
• Custom trending dashboard
• Statistical reporting
• Slow roll monitoring
• User activities tracking
Optimization Models
• 13 optimization models using NLP and MINLP methods
Symptom
Causes
Ref: EGUE 3-161972; “Combining AI and Prescriptive Analytics for reaching realistic Operation
Efficiency and Optimization”; Mohammed Batouq; Ali Alwadi; Samy Achour; Mark Nixon
Emerson Confidential 17
Power Generation
Import / Export Energy Management
System
Combustion Gas
Turbine Generators
HRSG Utilities North Steam Boilers
Steam Generation
South Steam BoilersHRSG NGL
Oil Plants
Pump Stations
M
NGL Plants
M
ST
• Energy KPIs Management
• Energy Optimization
• Condition based monitoring
AL Stabs AXL Stabs GC Stabs
DC2
Power Steam
ST
KNet
Analytics
KNet
online
Sensor
data Ref: EGUE 3-161972; “Combining AI and Prescriptive Analytics for reaching realistic Operation
Efficiency and Optimization”; Mohammed Batouq; Ali Alwadi; Samy Achour; Mark Nixon
Emerson Confidential 18
Dynamic Targeting
Equipment Availability
Operating Modes
Special Events
Process Scenarios
Best Performance
Dynamic
Targeting
Equipment that is not available is excluded from
the key performance indicators calculation
Energy consumption depends on the
stabilization depth
e.g. slow roll equipment, extended startup
boilers
Crude type changes
Best performance identification and
baseline modeling
Ref: EGUE 3-161972; “Combining AI and Prescriptive Analytics for reaching realistic Operation
Efficiency and Optimization”; Mohammed Batouq; Ali Alwadi; Samy Achour; Mark Nixon
Emerson Confidential 19
Business Results Achieved
Energy savings were estimated to be $22M per year
Increased visibility of the operations performance from the operator level to senior management for faster and informed decisions
The problem-to-resolution cycle time was significantly reduced
Best values and set points of key parameters for optimal distribution and increased profitability
Operation knowledge was retained, enhanced and shared
Ref: EGUE 3-161972; “Combining AI and Prescriptive Analytics for reaching realistic Operation
Efficiency and Optimization”; Mohammed Batouq; Ali Alwadi; Samy Achour; Mark Nixon
Integrated Asset Performance Platform
Empowered to
Collaborate
Health Status
Notifications
Health & Performance of all
Assets in one Consistent Platform
Predictive push alerts to right people
Enable cross-functions
Collaborations
Easy analytics
deployment for SME
Maintenance Work Order
One Consolidated Platform for all Assets
CMMS Integration
Historical & Live Data Sources for
Analytics
Device & Machinery DiagnosticsCondition-Based Analytics
Asset HealthPre-Configured Analytics
Asset Health & EfficiencyIntegrated Multi-Asset Analytics
Heat
Recovery
Coriolis
Vision of Digital Refinery of Future
Pervasive
Sensing
Root Cause
Identification
Historical Data
Control System
Predictive
Analytics
CMMS
Work Order
GenerationStore Room Parts Kit
Work Permit Generation
Maintenance
Team Notification
Perform
Maintenance
PdM System
Energy & Production Optimization
Prescriptive
Analytics
Data
Analytics
Edge, On-Premise,
and Cloud
Connectivity
ServicesConsulting &
Implementation
DIGITAL
TRANSFORMATION
DIGITAL
FOUNDATION
As-a-
Service
Models
Connected ServicesAsset Expertise and Actionable Insights
SoftwareCloud-Deployed Applications
Asset Performance PlatformEnterprise Analytics & Collaboration
Platforms
& Software
Production
Optimization
Operator
Performance
Control & Safety
Systems
SCADA
Project, Lifecycle,
and Educational
Services
Asset HealthPre-Configured Analytics
Asset Health & EfficiencyIntegrated Multi-Asset Analytics
Secure
ConnectivityData Integration & CybersecurityEmbedded Security at All Levels
Industry Expertise:Projects & Operations
Shutdowns, Turnarounds,
& OutagesDigital Strategy & Cybersecurity
Secure First MileSecure Data Pathways to External Applications and Experts
Device & Machinery DiagnosticsCondition-Based Analytics
Digital TwinsPlant & Asset Optimization
Personnel EffectivenessDigitally-Enabled Work Processes
Pervasive
Sensing
Radar
Level
Non-Intrusive
Temperature AcousticPressure
Gauge
Toxic
Gas Vibration LocationFlow Valve
Position
Non-Intrusive
CorrosionIntelligent
Field
Devices
PneumaticsValves
Measurement
Instrumentation
The Plantweb Digital Ecosystem: Enabling Top Quartile Performance With the
Industry’s Broadest Integrated Portfolio of Digital Transformation Solutions
Emerson ConfidentialSource: Emerson Internal Research
Application of Digital Refinery of Future
Emerson Named ‘Industrial IoT Company of the Year’ from IoT Breakthrough